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S Save This Manual ' _ For Future Reference owner's manual MODEL NO . 113.196221 113.196321 SAW WITH LEGS or 113.196421 CONTRACTOR'S SAW Serial Number . _ ' _ E _ A / F _ / SI : RI1FT $ M RN Model and serial numbers may be found at the front of the base . You should record both 10 - 1NCH RADIAL SAW model and serial number in a safe place for future use . FOR YOUR : SAFETY â¢ assembly READ ALL â¢ operating INSTRUCTIONS â¢ repair parts CAREFULLY \ Sears Roebuck and Co . , Hoffman Estates , IL 60179 U . S . A . Part No . SP5667 Printed in U . S . A .
Table of Contents Section Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Crosscutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Ripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Cutting Aides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 FULL ONE YEAR WARRANTY ON CRAFTSMAN STATIONARY TOOL If , this stationary tool fails due to a defect in material or workmanship within one year from the date of purchase , CONTACT THE NEAREST SEARS SERVICE CENTER IN THE UNITED STATES and Sears will repair it , free of charge . This warranty applies only while this product is in the United States . If this Radial Saw is used for commercial or rental purposes , this warranty will apply for ninety days from the date of purchase . This warranty gives you specific legal rights , and you may also have other rights which vary from state to state . SEARS , ROEBUCK AND CO . , DEPT 817WA , Hoffman Estates , IL 60179 U . S . A .
Safety This manual has safety information and M _ or Hazards instructions to help users eliminate or reduce Three major hazards are associated with the risk of accidents and injuries , including : using the radial arm saw for ripping . They i . Severe cuts , and loss of fingers or other are outfeed zone hazard , kickback , and body parts due to contact with the blade . wrong way feed . 2 . Eye impact injuries , and blindness , from This section only briefly explains these haz - being hit by a thrown workpiece , workpiece ards . Read the ripping and crosscutting safe - chips or pieces of blade . ty sections for more detailed explanations of these and other hazards . 3 . Bodily impact injuries , broken bones , and internal organ damage from being hit by a thrown workpiece 4 . Shock or electrocution Outfeed Zone Hazard 5 . Bums . Ai _ kDANGER Safety Symbol and Signal Words An exclamation mark inside a triangle is the safety alert symbol . It is used to draw ' attention to safety info _ Tna - tion in the manual and on the saw . It is If you reach around the blade to the outfeed followed by a signal word , DANGER , side when ripping , and try to hold down or WARNING , or CAUTION , which tells the pull the workpiece through to complete a level of risk : cut , the rotational force of the blade will pull your hand back into the blade . , _ DANGER : means if the safety infor - mation is not followed someone will be seri - Fingers will be cut off . ously injured or killed . Read and follow the information and A , _ WARNING : means if the safety infor - instructions under ripping safety . mation is not followed someone could be seriously injured or killed . A , _ CAUTION : means if the safety infor - mation is not followed someone might be inj are & Read and follow all safety information and instructions .
Safety Kickback Hazard Kickback is the uncontrolled propelling of WARNING the workpiece back toward the user during ripping . The cause of kickback is the binding or pinching of the blade in the workpiece . Several conditions can cause the blade to bind or pinch . KICKBACKIII _ When a workpiece kicks back , it could hit hard enough to cause internal organ injury , broken bones , or death . Read and follow the information and instructions under ripping safety . Wrong Way Feed Hazard Wrong way feed is ripping by feeding the workpiece into the outfeed side of the blade . WARNING The rotational force of the blade can grab and pull the workpiece . Before you can let go or pull back , the force could pull your hand along with the work - piece into the blade . Fingers or hand could be cut off . Wrong Way Feed The propelled workpiece could hit a by - stander , causing severe impact injury or death . Read and follow the information and instructions under ripping safety . 4
Safety Guard Function and Features The guard is a very important safety feature , designed to reduce the risk of injury associ - ated with blade contact . Install the guard correctly . Follow the specific instructions in the ripping and crosscutting sections to set and use the guard correctly for each ty pe of cut . Guard Features Include : 1 A non - moveable metal upper portion , Handle ! Squeeze Trigger ( Upper Guard ) which is fastened to the motor by the guard clamp screw , and which fully covers the upper half of the blade . 2 . A moveable clear plastic portion , ( Plastic Lower Guard ) which partially cov - ers the lower half of the blade . It protects against contact with the side of the blade during crosscutting when blade is in its rear - most position and the guard is resting on the table , so the leading and trailing teeth of the blade are not exposed . It also protects against contact with the outfced side of the blade during ripping , and acts as a barrier to prevent wrong way feed . Pawls / Riving 3 A squeeze trigger in the saw handle to Knife Knob rally raise the clear plastic guard at the start of a crosscut . Note : 1 " his ' is necessary Upper Guard Plastic Lower Guard because the guard will not automatically Hold Down raise to clear the fence . Knob 4 . A hold down to be lowered to just clear the top of the workpiece for ripping . It acts a _ a barrier to the infeed side of the blade , keeps the workpiece from fluttering , and acts as a sawdust deflector . It is Riving locked / unlocked by the hold down knob . Knife 5 A riving knife to be lowered to the table Pawls for ripping . It keeps the workpiece kerf open , thereby reducing blade pinching and the risk of kickback . It also acts as a barrier ? to the hazardous outfeed side and prevents Hold Workpiece Down wrong way feed . It is locked / unlocked by
Safety the pawls / riving knife knob . When lowered for crosscutting , it acts as a barrier to the leading edge of the blade . 6 . Set of pawls to be lowered to the work - piece surface for ripping . They allow the workpiece to pass freely from infeed to out - feed side , but help stop the kickback motion Guard Tab from ouffeed to infeed side by grabbing into the workpiece surface . Pawls must be re - set each time a different thickness workpiece is cut . 7 . A guard tab to manually raise the plastic guard at the start of ripping unusual work - pieces whose size / shape do not cause the guard to raise automatically . _ CAUTION Hazards Associated with Clear Portion of Guard Clear plastic portion of guard can get caught or jam in fence or table The following safety information applies to kerfs . Read and follow the warning all blades and accessories . on the guard : WARNING Clear plastic portion of guard will , _ WARNING : not provide any protection during TO AVOID INJURY crosscutting if blade is pulled over SHUT OFF POWER your hand , or your hand enters BEFORE CLEARING A blade path from front or rear of JAMMED LOWER GUARD blade . Fingers or hand can be cut or cut off . WARNING Clear plastic guard will increase risk of certain hazards : â¢ During rip and bevel cuts , narrow â¢ Cut off pieces can jam between guard and blade . Turn saw off and cut - off pieces can be pinched between guard and blade . Cut - off wait for blade to stop before freeing pieces can kickback . jammed guard or blade . â¢ In bevel position blade teeth are â¢ Workpiece or cut - off pieces can fully exposed . Fingers or hand can be violently thrown by blade . Wear be cut off . safety goggles . Stand out of work - piece path .
Safety Safety Instructions Read and follow all safety instructions . Personal Safety Instructions 1 . Wear safety goggles labeled " ANSI Z87 . 1 " on the package . It means the goggles meet impact standards set by the American National Standards Institute . Regular eye - glasses are not safety goggles . Safety Goggles 2 . Wear close fitting clothes , short sleeved shirts , and non - slip shoes . Tie up long hair . Do not wear gloves , ties , jewelry , loose clothing , or long sleeves . These can get Dust Mask caught in the spinning blade mad pull body parts into the blade . 3 . Wear dust mask to keep from inhaling fine particles . 4 . Wear ear protectors , plugs or muffs if you use saw daily . 5 . Keep good footing and balance ; do not Ear Protectors over - reach . Work Area Safety Instructions 1 . Keep children , pets , and visitors out of work area ; they could be hit by a thrown workpiece , workpiece chips or pieces of blade . 2 . Turn saw off , remove yellow key , and unplug before leaving work area . Do not leave until blade has stopped spinning . 3 . Make work area child - proof : remove yel - low key to prevent accidental start - up ; store key out of sight and reach ; lock work area . 4 . Keep floors clean and free of sawdust , wax and other slippery materials . 5 . Keep work area well lighted and unclut - \ tered . \ 6 . Use saw only in dry area . Do not use in \ wet or danap areas .
Safety Saw Safety Instructions 1 . Use guard , pawls and riving knife accord - 6 . Before turning on saw , clear table of all ing to instructions . Keep them in working objects except workpiece to be cut and nec - order . essary fixtures , clamps , or feather - boards . 2 . Routinely check saw for broken or dam - 7 . If blade jams , turn saw off immediately , aged parts . Repair or replace damaged parts remove yellow key , the free blade . Do not before using saw . Check new or repaired try to free blade with saw on . parts for alignment , binding , and correct 8 . Turn saw off if it vibrates too much or installation . makes an odd sound . Correct any problem 3 . Unplug saw before doing maintenance , before restarting saw . making adjustments , correcting alignment , 9 . Do not layout , assemble , or setup work or changing blades . with saw on , or while blade is spinning . 4 . Do not force saw . Use saw , blades and 10 . Keep saw table clean . accessories only as intended . 11 . Store items away from saw . Do not 5 . Have yellow key out and saw switched off climb on saw or stand on saw table to reach before plugging in power cord . items because saw can tip over . Workpiece Safety Instructions 1 . Cut only wood , woodlike or plastic mate - fins . Do not cut metal . 2 . Cut only one workpiece at a time . Stacking or placing workpieces edge to edge can cause user to lose control of workpiece .
Safety 3 . Rip only workpieces longer than the diameter of the blade . Do not rip workpieces that are shorter than the diameter of the blade being used . 4 . Workpieces that extend beyond the saw table can shift , twist , rise up from the table , or fall as they are cut or afterwards . Support workpiece with table extensions the same height as the saw table . 5 . To prevent tipping , support outer ends of extensions with sturdy legs or an outrigger . 6 . Do not use another person to help support workpieces or to aid by pushing or pulling on workpieces , because these actions can cause kickback . Use table extensions . 7 . Use clamps or vice to hold workpiece . It's safer than using your hands . Blade Safety Instructions 1 . Use only blades marked for at least 3450 5 . Do not overtighten blade nut because blade collar could warp . rpm . 2 . Use only 10 " or smaller diameter blades . 6 . Do not turn saw on and off in rapid sequence because blade can loosen . 3 . Use blades for their recommended cutting procedures . 7 . Blade should stop within 15 seconds after saw is switched off . ff blade takes longer , the 4 . Keep blade sharp and clean . saw needs repair . Contact Sears Service Center .
Safety Note where they are located on the saw . On - Product Safety Labels Read and follow the safety information There are several safety labels on the saw . and instructions in these labels . Refer to They alert the user to hazards explained in the manual for detailed explanations and the manual and remind the user how to instructions . avoid the hazard . / At the outfeed side , to the right of the guard near the saw handle is this safety label to alert you to wrong way feed : I TOAVOID \ \ INJURY DO \ , . NOT FEED \ MATERIALINTO \ I CUTTINGTOOL On the infeed side of the guard is this sde - ty label to remind you to lower the hold down to just clear the top of the work - piece for ripping : _ DANGER On the rear of the yoke , visible from the infeed side when the saw is in a rip position , is this safety label to alert you to outfeed zone hazard : 10
Safety Near the saw handle is dais safety label to " alert you to thrown objects and to remind , & WARNING you to wear safety goggles : On the clear plastic guard is this label : TO AVOID INJURY = SHUT OFF POWER ! BEFORE CLEANING A WARNING : I JAMMED LOWER GUARD , , DANGER On the bottom surface of the motor , visible when the cutting tool is horizontal , is this safety label alerting you to use a guard when edge molding , and to position the culling tool behind the fence : ( see Accessories Section ) , _ WARNING On the front of the yoke is dais general safety instruction label : 11
Assembly Introduction In order to get the most enjoyment out of your radial saw it is important that the machine by properly assembled , adjusted , and aligned . This procedure , although not difficult , takes time ; perhaps eight hours or longer for the inexperienced user . However , after this initial set - up a weekly tune - up can be completed in approximately ten minutes by checking the alignment and only adjusting those settings which are incorrect . Identify Parts The following parts are included : Note : Before beginning assembly , check that all parts are included . If you are missing any part , do not assemble the saw Contact your Sears Service Center to get the missing part . Sometimes small parts can get lost in pack - aghzg material Do not throw away arty packagi , g until saw is put together . Check pacl _ zgh _ g for missh _ g parts before contact - ing Sears . A complete parts list ( Repair Parts ) is at the end of the manual . Use the list to identify the number of the missing part . All models include : A . Basic Saw Assembly . . . . . . . . . 1 B C D B . Rear Table . . . . . . . . . . . . . . . . . . . . . . . . . . 1 F C . Spacer Table . . . . . . . . . . . . . . . . . . . . . . 1 D . Fence ( wooden ) . . . . . . . . . . . . . . . . . 1 E . Front Table . . . . . . . . . . . . . . . . . . . . . . . . 1 F . Table Support . . . . . . . . . . . . . . . . . . . . 2 G . Loose Parts Bag ( s ) . . . . . . . . . . . . * H . Bag Containing Accessory Guard . . . . . . . . . . . . . . . 1 J . Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 K . Stiffener , Side . . . . . . . . . . . . . . . . . . . . 2 d L . Stiffener , Front ! Rear . . . . . . . . . . 2 Model 113.196421 Only includes : K L M . Lower Stiffener . . . . . . . . . . . . . . . . . . 4 * Number varies ; bags can contain other smaller bags . Note : To make assembly easi - er keep contents of each bag tog _ Â¢ ther and separate from contents of other bags . _ 2
Assembly All models include : 5 / 16 " diam . hex nut ( 4 ) 5 / 16 " - 18 x 3 / 4 " long 1 / 4 " diam . hex nut ( 4 ) square head screw ( 4 ) _ llqqillllll [ tll1l / 4l " l - i2O0x 1 " long pan head screw ( 4 ) 1 / 4 " hex " _ _ IillJllilll _ liH _ l _ l _ lilllllil , lt _ 1 / 4 " - 20 x 1 - 3 / 4 " long 3 / 16 " hex " L ' _ pan head screw ( 1 ) # 6 - 32 x 1 / 2 pan head screw ( 4 ) wrench ( 2 ) # 10 - 32 x 7 / 8 " long _ lllllllllll ) pan head self threading screw ( 2 ) rip scale indicator ( 2 ) 1 / 4 " - 20 x 1 " long _ illllllllltlllllil7 slotted cup point set screw ( 1 ) yellow key ( 1 ) 17 / 64 " fiat washer ( 5 ) 1 / 4 " U - clip ( 1 ) 5 / 16 " flat washer ( 4 ) Â© 5 / 16 " lockwasher ( 4 ) - - 6 " Â© i ] twin nut ( 2 ) 1 / 4 " lockwasher ( 4 ) table clamp assembly ( 2 ) Â© - thumbscrew - square nut - clamp bracket tee nut ( 1 ) - cup washer 13
Assembly crank arm cap 1 / 4 " external tooth 1 / 4 " diam . x 5 / 8 " long Â© truss head screw ( 24 ) lockwasher ( 24 ) ( 40 for 113.196421 ) ( 40 for 113.196421 ) leveling foot ( 4 ) 5 / 16 " diam . external @ lockwasher ( 4 ) 3 / 8 " diatn , hex nut ( 8 ) C ) 11 / 32 " x 11 / 16 " x 1 / 16 " @ washer ( 8 ) 5 / 16 " diam . hex nut @ ( 4 ) 5 / 16 " diam . x 5 / 8 " long 1 / 4 " diam . hex nut hex head screw ( 4 ) Â© ( 24 ) ( 40 for 113.196421 ) Tools needed for Assembly and Alignment 7116 " Wrench @ ' _ 1 , ' 2 " Wrench Wrench @ . . . . . . . . @ 9 / 16 " Wrench Medium Screwdriver 15 / 16 " Wrench Pliers Phillips Screwdriver Framing Square Small Hammer Pencil I 14
Assembly 5 . Install one 3 / 8 - 16 hex nut completely onto _ k WARNING each of the leveling feet . Insert one leveling Plugging in saw during assembly foot through hole in bottom of each leg and could result in electrical shock , or install a 3 / 8 - 16 hex nut . severe cuts from contact with spin - 6 . To level steel legs , loosen nut on inside of ning blade . leg and turn nut on outside to raise or lower Do not plug in saw at any time dur - feet . Adjust all four levelers if necessary , and ing assembly . then tighten nuts on inside of leg . Plug in saw only when it is to be used . Note : These levelers " are not intended for Assembly Steps height adjustment . It is important for your safety and to get For model 113.196421 only accurate cuts that you put the saw together From among the loose parts , find the follow - according to these instructions . ing hardware : Fol ! ow these steps in order . 16 Truss Head Screws 1 / 4 - 20 x 5 / 8 Assembling steel legs 16 Lockwashers , 1 / 4 " external For easy assembly it is recommended to fin - ger tighten all screws , lockwashers , and hex 16 Hex Nuts , 1 / 4 - 20 nuts until the legset is fully assembled . Then ! . Attach the lower leg stifeners to the steel go back and tighten all nuts securely . legs using two ( 2 ) screws , lockwasher and From among the loose parts , find the follow - hex nuts on each end . For the short side of ing Hardware : stand , use the inside holes in the stiffeners . 24 Truss Head Screws , 1 / 4 - 20 x 5 / 8 For the long side , use the outside holes . 24 Lockwashers , 1 / 4 - External 2 . Tighten all nuts securely . 24 Hex Nuts , ! / 4 - 20 8 Hex Nuts , 3 / 8 - 16 X = Location of Truss Head Screws 4 Leveling Feet 1 . Insert three truss head screws through the Front / Rear Stiffener three holes near the top of one Leg . Place the Side Stiffener up to the Leg , as shown , so that the three screws line up with the holes in the Side Stiffeners marked with an " X " in the illustration . 2 . Place a lockwasher and hex nut on each screw and finger tighten the hex nut . Side Truss Head 3 . Following the same procedure as above , Stiffener Screws continue to fasten together the remaining Legs , Side Stiffeners , and Front / Rear Stiffeners as illustrated . 4 . Set stand upright and securely tighten all nuts . 3 / 8 " Hex Nuts Leveling Foot 15
Assembly Leg Leg Mounting Saw / , , / 1 . From _ mlong tile loose p ' - w'ts , find the fol - - % , / / lowing hmdware : 4 ttex tlead Screws , 5 / 16 - 18 x 5 / 8 4 Lockwasher , 5 / 16 in . External Type 8 Washers , 11 / 32 ID 4 Hex Jam Nuts , 5 / 16 - t8 2 . Place saw on legs so that holes in bottom of saw line up with holes marked X in top of legs . 3 . Install screws , washers and nuts as shown . If you mount the saw on any other Craftsman base or Slat bench , make sure Elevation Crm _ k has proper clearance to Front / rotate . The saw must be bolted down . Sliffener Position saw to slope slightly rearward , so when tile carriage is installed it will not roll _ WARNING forward due to gravity . SawBase Saw must slant slightly towards Hex Head _ I rear to keep blade carriage from rolling forward . Workpiece or saw can move unexpectedly if leg set rocks . Fingers , hand or arm could be cut off by blade contact . Adjust Stiffener leveling feet before using saw . Flat Washer Lockwasher Hex Nut Attach Elevation Crank . Install crank on elevation shaft . Be sure setscrew is tightened on flat of shaft . Shipping Block Elevation Crank ( Turn clockwise to raise arm ) \ \ \ \ Elevate arm approximately 3 to 4 inches . Remove shipping block mid discurd . 16
Assembly Attaching Carriage - Motor to Arm Remove carriage stop screw , lockwasher and tag . Read and understand warning tag before discarding . Warning Tab ( _ j _ Lockwasher _ , . . . . . . . , . _ - _ Stop Screw _ " ' - ' - Hex " L " Wrench ( Supplied ) Lock miter / arm lock before proceeding . Push toward rear of Holding carriage assembly with both hands , saw to lock Miter / Arm carefully start and slide the carriage onto the Lever tracks . The assembly must be held parallel with the arm so that all four bearings slide smoothly onto the arm , preventing any excessive strain on bearings and track . WARNING Reinstall carriage stop screw and Iockwasher to prevent carriage from rolling off arm . Remove two ( 2 ) motor packing studs that are threaded into bottom of motor . Arm Cap Install arm cap and arm cap trim Screw , _ WARNING Make certain power cord is unplugged . 1 Insert finger under left end of switch lever and pull out to the " ON " position . 2 Place arm cap in position and install with ( 2 ) 10 - 32 x 7 / 8 self threading screws . 3 . Push switch to " OFF " position . 17
Assembly Remove saw blade . 1 . Tighten carriage lock knob , located on right side of ann . 2 . Loosen guard clamp screw approximately Purl down 4 turns . to | oo _ er } 3 . Use one hand to lift the clear plastic guard Blade Rotation at the front of the saw . 4 . Use the other hand to grasp the rear of the guard ( below the dust elbow ) . 5 . Rotate the entire guard assembly forward approximately 45 Â° . 6 . Remove the guard assembly . 7 . Motor shaft has left hand threads . Hold shaft wrench and rotate arbor wrench down ( clockwise ) . 8 . Remove shaft nut , outer collar , saw blade , and inner collar . Set aside and out of the way . Attach Table Supports 1 . Set out : - two table supports - four 5 / 16 " 18 x 3 / 4 " long square head Table Table screws Support Support - four 11 / 32 " x 7 / 8 " x 1 / 16 " flatwashers \ - four 5 / 16 " lockwashers - four 5 / 16 " hex nuts SCreWS Here 2 . Attach supports to side frame , making sure to use correct holes in table supports and side frame : Use two screws per support Nut " " _ ( insert screws through base and then sup - Lockwasher port ) ; on end of each screw put a flat washer , Flatwasher Base lockwasher and nut then finger tighten so table supports rest in lowest position . _ ] Front Mount rails using these holes This concl _ tdes the assembly section . Except for installing table bonds , fence , and table clamps the saw should be completely assembled . The next section deals with adjusting your saw to remove ' all " looseness " in order to get accurate cuts . 18
Adjustments Miter / Arm Lock Lever Arm Lock Adjusting Wheel With the arm at an " unindexed " position and the miter lock applied , the locking action should feel tight and secure . Considerable effort should be required to move the ann back towards 0 Â° . Its is " always possible to force the arm because of the leverage advantage the long arm provides . However , the arm should resist moving when a reasonable amount of force is applied . To check follow these steps : 1 . Pull miter / arm lock forward to unlock and rotate ann to approximately 30 Â° left or right . 2 . Lock miter / arm lock by pushfng handle toward rear of saw . 3 . Apply pressure as shown above . 4 . If the arm moves easily : a . Unlock miter lock . b . Locate the adjusting wheel as shown . c . Turn wheel clockwise to tighten , counterclockwise to loosen . 5 Repeat steps 1 , 2 , 3 above and readjust as Arm Lock necessary . Adjusting Wheel 19
Adjustments Yoke Clamp Adjustment Yoke Lock Handle To check the yoke clamp adjustment follow these steps : 1 . Pull the yoke lock handle towards the front of saw to unlock yoke . Pull forward on the yoke index lever ( on the left side of car - riage ) to disengage index pin . 2 . Swivel the motor halfway between the crosscutting and rip position so the index pin is not engaged . 3 . Lock the yoke lock handle . 4 . Grasp the motor with both hands and try to swivel it back into the crosscut position . It should not move . 5 _ If it does move tbllow these steps : a . Rein , we arm cap . Arm Cap Lock Washer b . Remove carriage stop screw and lock - washer with a 1 / 4 inch hex - L wrench . c . Grasp the carriage assembly , move it careful ] v off the end of radial ann , hold - Screw ing it parallel to the radial arm until all carriage bearings are free of their tracks . d . Rest lhe motor and carriage assembly on saw frame . e . Set yoke lock handle at unlocked posi - Carriage Stop Screw tion . Tighten nut with 15 / 16 " x _ , renctl , Hex " L " Wrench until lock handle locks mid - way between ( 1i44nch ) the two legs of the yoke . / f . ltold the motor and carriage assembly 15 / 16 " Wrench / parallel to radial arm and starl the rear bearings onto the tracks . Continue to hold the assembly parallel to the tracks unlil the forward bearings are on the tracks . g . Slide the carriage rearward on the radi a [ arn - t tmlld install the carriage stop screw and lockwashcr . h . Instal ! arm cap . I i . Rcpcul steps 1 4 . Read usl if nccc _ < s ' , try . 2O
Adjustments Bevel Lock Lever l 1 Â© The purpose of the bevel lock lever is to lock the motor at any angle . To check follow these steps : Bevel 1 . Unlock the bevel lock lever . Move the , Index Pin bevel index pin to the left and rotate the saw to approximately 30 Â° . Lock the bevel lock lever . 2 . Use both hands as shown and try to force the motor out of position . If the motor Bevel Lock moves , the bevel lock lever needs to be Lever tightened . On the other hand if it is extreme - ly hard to lock the bevel lock lever it has been over - tightened . 3 . Follow these steps to adjust : a . Remove the socket set screw with hex wrench as shown . \ b . Use the bevel lock lever as a wrench to tighten or loosen the clamp bolt . Do not over tighten . [ _ Bevel Lock c . Repeat steps 1 and 2 . Re - adjust if nec - essary Lever d . Replace bevel lock lever in the locked position . Lockwasher e . Tighten the set screw . Note : The clamp bolt has a left handed thread . Therefore , to increase the clamping 1 / 8 " Hex " C " Wrench effect , rotate the bevel lock lever - when used as a wrench - from right to left , or clockwise when viewed from above . If you accidentally rotate it the wrong way and dis - engage the bolt from the matching steel nut , it will be necessary to remove the Yoke Handle , and Bevel Scale , in order to rein - \ stall the bolt into the nut . Bevel Lock Lever In Locked Position 21
Adjustments Arm to Column Adjustment If you can move the end of the radial arm up and down when the ann is unlocked , adjust 3 / 8 - 16 Bolts as directed below : a . Remove two ( 2 ) screws from rear cover plate . Tighten evenly top two 3 / 8 - 16 bolts until arm moves firmly . There should be no vertical or horizontal movement in the arm when miter / arm lock is locked and unlocked . 3 / 8 - 16 Nuts b . Bottom two nuts should be snugged evenly , but not nearly as tight as top two bolts . c . Re - Install Rear Cover Plate . Adjusting Column Tube in Column Support This adjustment serves two purposes ; â¢ To remove any looseness between the col - umn tube and column support to insure accurate cuts ; and â¢ To allow the column tube to raise and lower smoothly . Note : The following adjustment is very criti - cal All future alignment procedures rely on this adjustment being performed correctly . All looseness must be removed . 1 . Index and lock arm at 0 Â° Miter . While holding the arm with one hmad , hold fingers of other hand as shown , between column tube and column sup - port . Apply gentle side - to - side pressure at end of arm . Any side - to - side or rotational movement can be felt with finger at arrow location . If looseness exists , the following adjustments are required . 22
Adjustments 2 . lax ) sen ( 2 ) 1 / 4 - 20 Gib socket cap screws Front on the left side at the rear of the column sup - port slightly ( 1 / 2 turn ) . Hex " L " Wrench _ _ " _ ( Supplied ) 1 _ I - 3 . Elevate , and then lower the Ann : a . If the column tube binds and elevation Front is difficult , loosen two 5 / 16 - 18 plated J bolts on front side of the column support 5 until you achieve smooth but firm eleva - / Bright Plated t tion . 1 Bolts b . If the column tube moves side - to - side within the column support , tighten the two 5 / 16 - 18 plated bolts until movement disappears - elevation should be smooth and firm . 4 . Now tighten the ( 2 ) 1 / 4 - 20 Gib socket Â© cap screws until no noticeable rotational play exists between Column Tube and Column Support as shown in step 1 . 5 . Turn the elevation handwheel to raise and lower the saw . If movement is too difficult slightly loosen the socket cap screws . 23
Adjustments Adjusting Carriage Bearings ff the carriage bearings are loose it not only allows the saw blade to move up , down , and sideways but also results in inaccurate cuts . Before following these steps make sure the tracks ( steel rods ) and carriage bearings have been cleaned by wiping them with a clean cloth . When properly adjusted , the top and bottom face of all four bearing grooves should be in contact with the arm tracks for their entire length and carriage should roll smoothly with some resistance . To test for looseness between bearings and tracks on radial arm , perform the following steps . 1 . Remove left - hand carriage cover . ( 2 screws ) 2 . Push the carriage to its full rearward posi - tion . 3 . Grasp front carriage bearing as shown and hold as tight as possible . At the same time pull carriage forward . If you can stop the bearing from turning , it requires adjusting . 4 . Check rear bearing in the same manner . 5 . Adjust as follows : a . Use two 1 / 2 " wrenches to loosen nut just enough to permit the eccentric screw to turn . b . Rotate the eccentric screw a partial turn Washer Oefl or right ) as required to take up loose - Eccentric Assembly ness . Screw c . Hold the head of eccentric screw in the Carriage Carriage position established in the preceding step Bearing and tighten nut on underside of carriage . Correct adjustment exists when you can - not keep the bearings from turning . Plain However , excessive bearing pressure will Washer Loekwasher cause difficult operation and rapid wear . Nut d . Install carriage cove1 ; Left Side Carriage Bearings 24
Adjustments Positioning Table Supports ! Installing Front Table / Leveling Front Table Note : The goal in aztjusting the table supports and leveling the front table is to make sure that the table is the same distance from the radial arm at all points . This ensures that when the table and blade are installed the clearance between them will be equal at all points . Positioning Table Supports 1 . Release bevel lock lever , move bevel index lever to the left and rotate the motor to position arbor shaft down . Lock bevel lock . Index Release Unlock Position 2 . Unlock and hold nfiter / arm lock lever in Miter ! Arm index release position as shown . Position Lock Handle arm against left stop ( approximately 50 Â° miter ) . Loosen carriage lock knob and posi - tion arbor shaft directly over left hand chan - nel . Note : For safety reasons in accordance with the UL standard , stops have been provided to prevent 360 Â° rotation of the radial arm . BevelLock 3 . Slide the arbor wrench handle between Lever end of motor shaft and table support to act as a feeler gauge . Carefully lower the motor with elevation crank until the end of shaft is just touching the arbor wrench . The wrench should slide back and forth with only slight Arbor Wrench resistance . Tighten screw " ' A " . Screw " A " Note : Do not change this elevation setting until both left and right hand table support channels have been adjusted . 4 , Move arm and carriage to screw " B " . Adjust position of table support so that the arbor wrench just slips between the end of the motor shaft and the support . Tighten screw " B " . 5 . Move arm and carriage to right hand table ArborW _ , _ . _ _ _ support and level in the same manner as in step 4 . 6 . Recheck both support channels to make sure that tightening screws did not affect the _ l - _ - ' " / / J Table Mounting accuracy of the adjustment . / j / Support Channel YScre / w " B " ( Left Hand ) 7 . Elevate saw and return motor to horizon - tal position to provide clearance for installa - Screw " A " tion of front work table . 25
Adjustments Installing Front Table 1 . Set out : - front table - tee nut - 1 / 4 " U - clip - 1 / 4 " diam . x 7 / 8 " long cup point set screw - four 1 / 4 " diam x 1 " long pan head screws - 1 / 4 " diam . x 1 - 3 / 4 " long pan head screw - five 17 / 64 " I . D . x 5 / 8 " O . D . flat washers - four l / 4 " lock washers - four 1 / 4 " diam . hex nuts . T - Nut 2 . Identify top and bottom of table : top has counterbored holes . Place table bottom side up on solid surface . Hammer tee nut into leveling hole . ( This hole is not counter - bored from the top ) . 3 . Snap U - clip onto front edge of base so hole lines up with hole just to the left of cen - ter notch . 4 . Place table , top side up , on saw so center counterbored hole lines up with hole in U - clip . Note : Table will extend over front edge of saw frame . 26
Adjustments 5 . Drop a flat washer into each counter - 1 / 4 - 20 x 1 " Pan Head Screw bored hole . 1 ; 4 - 20 x | - 3 / 4 " 17164 " Pan Head Screw Flat Washer 6 . Start 1 - 3 / 4 " long pan head screw through _ Front Table center hole and into U - clip , but do not fully tighten . 7 . Start cup point set screw through leveling hole and into tee nut , but do not fully tight - en . Hex Nut 8 . Put 1 " long pan head screw in each of four remaining holes and through matching holes 1 / 4 - 20 x 7 / 8 " Cup Point Set Screw in table supports . On end of each screw , put lock washer then nut and tighten with screw - driver . Make Front Table Flat Rear Table Board 1 . Place rear table on its edge , across center _ _ HDoolwdn Screw Leveling ] j of front table . Check for gap between sur - Set Screw faces . If there is less than 1 / 32 " gap , tighten cup point set screw until it touches frame ( look underneath table ) , then tighten center ( 1 - 3 / 4 " long ) pan head screw . If there is more than 1 / 32 " gap , close gap by raising or lowering center of front table : to raise center , tighten cup point set screw against frame ; to lower center , tighten center ( 1 - 3 / 4 " long ) pan head screw . 2 . When gap is closed , make sure cup point set screw touches frame ( look underneath table ) , and center ( 1 - 3 / 4 " long ) pan head screw is tightened . This concludes adjusting your saw where you have removed " all " looseness " or slack between the different parts of the saw . The next section deals with actually aligning the sawblade to get accurate cuts . 27
Alignment This section applies to all three models cov - , _ WARNING ered by this manual . Plugging in saw during alignment could result in accidental start - up The saw and blade must be aligned correctly and severe cuts from contact with for two reasons : spinning blade . 1 ) to prevent binding of the blade and work - Do not plug in saw at anytime dur - piece , which can cause jams , kickbacks , or ing alignment or adjustment . thrown workpieces ; Plug in saw only when it is to be used . 2 ) to make accurate cuts . Check Framlng Square Alignment and Adjustment Steps This edge must be straight The following alignments and adjustments / must be made in order . If you miss an I I adjustment , you must go back , make the I I missed adjustment , and repeat all steps from I Draw light that point on . line on board f along this edge These adjustments are like fine tuning a L : piece of equipment . Often , a series of steps must be repeated more than once in order to / get the adjustment right . There are many Should be no gap or overlap here when square is flipped over to dotted position . adjustments to make . Because some adjust - ments may be awkward , you may want to ask someone to help you . Before you start , make sure the framing Blade square is true . Rotation Square Crosscut Travel The goal of this adjustment is to make accu - rate crosscuts . To do so , the radial arm must be square to the fence , otherwise , there will be a slight miter angle in all crosscuts . k _ o End of arbor wrench Squaring cross cut travel . _ / / resting on table 1 . Index but do not lock arm at 0 Â° miter . 1 _ fff _ 2 . Install saw blade as shown . Motor shaft has left hand threads . Saw Note : Do ru - ) tovertighten arbor nut . Use the Blade _ / _ arbor wrench to just " snug " it . Outor / li \ , hoot Collar ( ; _ _ i Motor Collar 28
Alignment Miter , Arm Lock Lever 3 . Lower arm until saw blade just clears the front table . Lock the yoke lock handle and bevel lock lever . 4 . Place a framing square on the table , as shown , with one leg of square t - manly against ( rear edge of front table . Position the blade and square until the leg of the square just Yoke Lock contacts a tooth of the blade . Mark this Handle tooth . ' Bevel Lock 5 . When the carriage is moved slowly back Lever and forth on the arm , the marked tooth Tooth should just touch the square at NI points . If marked tooth moves into or away from square the following adjustments are required : a . Loosen ( 3 ) 3 / 8 - 16 set screws in arm latch at rear of arm . 3 , ' 16 " Hex " L " Wrench b . Move the arm in direction to make ( Supplied ) marked tooth follow edge of square when the saw blade is moved " alongarm in a " cross cut " manner . c . Lock miter / arm lock . d . Retighten ( 3 ) setscrews in ann latch as fight as possible and recheck " cross cut " travel . Note : This squaring of the cross cut travel will simultaneously set both of the 45 Â° miter index positions . 6 . Set miter indicator on 0 Â° position using end of blade wrench . 29
Ali nment Front Install Table Clamps Spacer Rear Table Fence Table Table 1 . Insert fence , then spacer table , then rear \ table . L 2 . Set out two unassembled table clamps : - two cup washers - two clamp brackets - two square nuts - two thumbscrews 3 . Slip square nut into slot at top of clamp Square bracket . Nut 4 . Insert thumbscrew through rear opening , and turn c ! ockwise until it comes out other waCshPr . _ _ side about 1 / 2 " . Note : If you put screw in front opening , clamp will not work . Thumbscrew Clamp 5 . Tilt clamp bracket forward and snap into Bracket place in opening at rear of table support . 6 . Hold cup washer with concave side against rear table . Turn thumbscrew clock - wise until it snaps into washer . 7 . Repeat steps for other table clamp . 8 . Tighten thumbscrews to clamp table sec - tions in place . 3O
Alignment Square Blade to Table for Bevel Indicator Crosscutting The goal of this adjustment is to make the blade square to the table so that crosscuts will be accurate ; otherwise all crosscuts will have a slight bevel angle . 1 . Lower blade until it just dears front table . Lock bevel , miter , rip , and yoke locks . 2 . Place a framing square on the table with Rip the short leg against the saw blade and long Fence leg parallel to fence . Do not allow the square to rest against a " set - out " tooth ; it must rest flat against the blade side . 3 . If the saw blade is square with the table Square top ( no visible gap appears between the saw ( Place parallel to fence ) blade and square ) no adjustment is required . Set bevel indicator to 0 Â° reading . If the square does not touch the saw blade as shown ( with square leg held firmly against the table top ) , perform the following adjust - ments : SquareN _ ! I I I I ! I I Wrong Wrong Correct / I Table a . Tighten rip lock knob . b . Remove handle by removing 5 / 16 - 18 socket head screw and lockwasher . c . Slightly loosen the four socket head screws with 1 / 4 " Hex " L " Wrench . Rotate motor while holding square fn'rnly against , ( til saw blade and table top . d . Slightly tighten each of the four screws @ - - ' _ Jt _ / HeadScrew and recheck . . . Now tighten each screw tight . 5 / 16 " Lockwasher _ ' _ ' _ 1 . ; 4 " Hex " L " Wrench " _ ' _ e . Reinstall handle and adjust indicator to ( Supplied ) 0 Â° reading . f . Loosen rip lock knob . 31
Alignment Square Blade to Fence Left Hand Carriage Cover I The goal in setting the blade square to the fence is to reduce the risk of kickback when ripping . This adjustment will also reduce splintering of the workpiece and buming of Rip Fence the keff during ripping and crosscutting . 1 . Lower blade until it just clears table . 2 . Unlock rip lock , Pull blade forward to front of arm . Lock rip lock . 3 . Place square so short edge is against fence and long edge is against fiat surface of blade ( not on a tooth ) , just below blade collar . 4 . There should be no gap between blade Fence I and square . Note : Not all blades are perfect - ty flat . Check different points along blade surface by making quarter turns and looking Square ] _ for gap each time . Consider overall fit of blade . If there is no gap , no adjustment is needed . I 1 I I 5 . If there is a visible gap between the saw blade and square adjust as follows : a . Remove left hand carriage cover . b . Loosen the yoke lock handle . ( on right side of carriage ) . c . Loosen slightly the two hex - head screws holding yoke index pin . d . Rotate the yoke assembly until gap between the saw blade and square is elim - Hex Head Screws inated . e . Lock yoke lock handle . Retighten the two hex - head screws . f . Recheck blade squareness . g . Install carriage cover . Left side of Carriage h . Loosen carriage lock knob and return blade to rear of arm . Note : This alignment procedure will simul - taneously set both yoke indexing positions for blade in and out rip . 32
Ali , nment Make Blade Parallel to Table The goal of this adjustment is to keep the workpiece from being thrown or damaged . This adjustment will also reduce splintering of the workpiece and burning of the kerr during ripping and crosscutting . 1 . Lock arm in straight crosscut position . 2 . Pull blade forward and lock rip lock . 3 . Raise blade at least 2 " above table . 4 . Lock motor at 90 Â° bevel ( blade horizon - Correct tal ) . 5 . Place square so long side is on table under right side of blade , and short side hangs Blade down vertically at front of saw . 6 . Lower radial ann until blade surface , not a tooth , just rests on square . Square Table 7 . There should be no gap between blade and square . Note : Not all blades are perfect - Wrong Wrong ly flat . Check different points along blade surface by making quarter turns and looking for gap each time . Consider overall fit of blade . If there is no gap , no adjustment is needed . 8 . If there is a visible gap between saw blade andsquare , a bevel heel condition exists and adjustment is required . a . To correct , unlock bevel lock lever . Loosen the rear motor mount nut until you can rotate Cam . Rotate Cam as shown until gap between saw blade and square is eliminated . b . Tighten nut . c . Tighten bevel lock lever and recheck blade to square . d . Reposition motor to crosscut position with blade at rear of arm . 33
Alignment Installing and Adjusting Rip Scale Indicators . Screw # 6 - 32 x 1 / 2 Note : The rip scales and pointers are intended to be used for quick settings . For greater accuracy , take direct measurement between blade and fence . _ [ _ Jl ' _ , I Rip Scale 1 . Pre - assemble indicator and twin nut . Loosen but do not remove two screws which lndicator attach left hand carriage cover . 2 . Tilt carriage cover and install rip indicator Twin Nut with twin nut on inside of cover . Tighten carriage cover attaching screws . 3 . Loosen but do not remove rip lock knob Yoke Index Lever in right hand carriage cover . Install rip indi - Yoke Lock Handle cator . Tighten carriage cover attaching screws . 4 . With fence in its normal position ( next to front table ) , loosen yoke lock handle , pull yoke index lever forward and rotate yoke to the left to index yoke 90 Â° from the cross cut Table Front position . This will locate saw blade between Fence motor and fence . Lock yoke lock handle . / 5 . Position carriage until edge of blade , I when spun by hand , just touches front face [ of fence . The rip - scale indicator ( on the fight Table Spacer Board Table hand side of radial arm ) should now read " 0 " inches on upper portion of the blade " In - Rip " scale . If not , loosen screws and shift Rip Scale Indicator the indicator until it is aligned with the " 0 " mark , then tighten the screws . Note : With saw blade and fence in the posi - tion shown , the upper portion of blade " In - Rip " scale is used . Iffence is moved to extreme rear position , the lower portion of blade " In - Rip " scale would be used . O r ] _ Rip Lock Knob 34
Alignment 6 . The blade " Oul - Rip ' " scale indicator on left hand side of the radial arm is adjusled in essentially the same manner as blade " In - I Rip " indicator , except position blade with 2 J inches between fence and face of saw blade . The rip - scale indicator should be positioned to read 2 inches on upper portion of the blade " Out - Rip " scale . Note : With saw blade and fence in the posi - tion shown , the upper portion of the blade ' Out - Rip " scale is used . If fence is moved to J e _ rtreme rear position the lower portion of I 2 " - Measured from fence blade " Out - Rip " scale is used . to nearest blade tooth 7 . Loosen the yoke lock handle , pull the yoke index lever forward and return the blade to the crosscut position . Note : Blade is now aligned . It is important that you periodically check alignment and adjustment to insure accurate cuts and improve and safety of cutting procedures . Install Guard The guard is a very important safety feature . It covers a large part of the blade and helps protect against severe cuts . Always use the guard . I . Lock motor at 0 Â° bevel ( blade vertical ) . 2 . Use one hand to lift clear plastic guard ; use other hand to grasp rear of guard ( below dust elbow ) . Position guard so riving knife laces front of saw . 3 . Tilt front of guard down about 45 Â° ; place over blade ; rotate guard to level position . Note : Make sure notc'h in guard fits onto tab on motor . This will prevent movement of guard about motor . Squeeze handle trigger to make sure it fully raises clear plastic guard . If it does not , remove and re - install , _ , uard , making sure that trigger mechanism engages pull link on guard . 4 . Tighten guard clamp screw . Parallel 35
Alignment Align Riving Knife to Blade The goal of this adjustment is to position the riving knife directly in line with the blade . Riving knife alignment is an important safe - ty factor . The riving knife rides in the kerf of the cut workpiece during ripping to keep the Fence _ _ RivPinagwlsKnife two sides of the workpiece from pinching on the blade . Blade pinching is a cause of kick - Correct : Blade and Riving Knife back . are in Line and Flat Against Fence . 1 . Lock yoke in in - rip position ( blade towards column , motor towards front of arin ) . 2 . Lower arm until blade just clears table . 3 . Unlock rip lock while holding up lower plastic guard , move yoke back until blade touches fence . Lock rip lock . 4 . Loosen pawls / riving knife knob . Lower riving knife to the table and tighten knob . Wrong : Riving Knife Wrong : Riving Knife The riving knife should rest flat against on Top of Fence . Away from Fence . fence . 5 . If adjustment is needed : Pawls / Riving Knife Knob i ) loosen riving knife bracket screw . ii ) slide riving knife so it rests ag _ finst fence . iii ) secure riving knife bracket screw . 6 . Raise riving knife and tighten pawls / riv - ing knife knob . Riving Knife Bracket Screw 36
Controls Bevel Index Lever r Lock Lever Yellow Key Function Control Operation / Comments Pull lever forward to release _ ter / Arm Lock Frees radial ann to move ; locks index then swing ann left or in any desired position ; pre - set right indexed positions at 0 Â° , 45 Â° L , 45 Â° R Hold in unlocked position while moving arm On - Off Switch Turns motor on / off Pull on , push off Requires yellow key Insert into on - off switch Allows saw to be switched on Yellow Key Remove after turning saw off Move bevel index lever to the Bevel Index Lever Indexes the saw blade to 0 Â° , 45 Â° , or 90 Â° pre - set index posi - left while positioning the blade , tions then release it 37
Controls Yoke Index Lever Table Clamp Bevel Lock Lever Elevation Crank \ Con _ ol Function Operation / Comments BevelLock Lever Frees motor to rotate ; locks in Pull lever to release and push to lock any desired position Support motor before unlocking because it can swing down quickly Bevel index lever must be un - indexed before moving motor Elevation Crank Raises / lowers radial arm Turn clockwise to raise , coun - terclockwise to lower Frees table sections to allow Table Clamp Tttrn clockwise to tighten , coun - terclockwise to loosen changing fence position Yoke Index I . ever Frees yoke to rotate between rip Pull the spring loaded yoke and crosscut positions pivot latch forward to release this pin 38
Controls Rip Scale & Indicator Rip Lock Yoke Lock Handle Saw Handle Bevel Lock Lever ( ontrol Function Operatio = _ iComments Yoke [ rock Handle Locks yoke in rip or crosscut Pull handle forward to release ; position push handle reward to tighten Yoke index lever must be un - indexed b @ ) re rotating yoke Rotate counterclockwise to Rip I . ock locks carriage to radial arm for ripping release carriage ; turn clockwise to Lock carriage in position Lock before rq ) ping Rip Scale & Rip Tells approximate distance Move blade carriage akmg arm Indicators between blade and fence when to align line on indicator with desired number on scale saw " is in in - rip or out - rip posi - tion Saw Itandle Provides grasping surface so Grasp to move blade carriage carriage can be moved . Squeeze tr _ , qer to fidly raise Contains trigger mechanism to cIear plastic guard . Clear raise clear plastic guard when guard must be raised over fence to crosscut making a crosscut 39
Controls Guard Clamp Screw Guard Pawls / Riving Knife Knob Bracket Riving Knife j tn Pawls Hold Down Control Function Operation / Comments Guard Clamp Secures guard to motor ; frees Turn counterclockwise to Screw guard for removal loosen , clockwise to tighten Guard Protects against contact with Upper part remains fixed in upper blade ; partially protects level position . Notch in guard against contact with lower fits securel ) , into matching tab blade ; acts as sawdust deflector on motor Clear guard is moveable : fully raise over fence to crosscut ; See Saw Handle ; most workpieces will automatically raise clear guard during ripping ; See Guard Tab Hold Down Turn counterclockwise to Frees hold down to move up Knob and down ; locks hold down in loosen , clockwise to tighten place Hold Down During ripping , acts as partial For ripping , lower hold down to barrier to infeed side of Made ; top of workpiece surface , then keeps infeed side of workpiece raise slightly and lock in place . from fluttering ; acts as sawdust For crosscutting lock in fully deflector raised position Riving Knife Prevents side to side movement [ x ) osen to align riving knife , Bracket of riving kqifc and provides then tighten means for adjusting alignment 4O
Controls Pawls / Riving Knife Knob Pawls \ Riving Knife Function Control Operation ! Comments Guard Tab Provides manual way to raise Push and hold until workpiece clear plastic guard during rip - clears guard , then release ping when workpiece fails to raise it Turn _ unterclockwise to Frees pawls and riving knife to Pawls / Riving Knife Knob loosen , clockwise to tighten independently move up and down Pawls During ripping , slow or stop For ripping , set pawl level on kickback by digging into work - workpiece surface . For safety piece ; when lowered during reasons set pawls before rip - crosscutting , provide partial bar - ping ; See Ripping Set - Up for details and illustrations tier to leading edge of blade Reduces kickback by keeping For ripping , lower to table Riving Knife For safety reasons riving knife kerr open ; when lowered during must be in line with blade . See crosscutting , provides partial barrier to leading edge of blade Alignment : Riving Knife to Blade 41
Electrical Connections , _ WARNING Motor Specifications If not properly grounded , this power The AC motor used on this saw is a capaci - tool could cause electrical shock , tor - start , non - reversible type . The models particularly when used in damp covered in this manual have the following locations . specifications : Specification : Model Model Model _ IL WARNING 113.196221 113.196321 113.196421 If electrical shock occurs , your Rated H . R 1.5 1.5 1.5 reaction to shock could bring hands Max Developed H . R 2.5 2.75 3.0 into contact with blade . Voltage 120 120 / 240 120 / 240 _ , WARNING Amperes l 1 12 / 6 13 / 6.5 To avoid electric shock or fire , Hertz ( cycles ) 60 60 60 immediately replace worn , cut , or Phase single single single damaged power cord . RPM 3450 3450 3450 , arbor Shall Rotation clockwise clockwise clockwise The unit is wired for 120V and has a plug that looks like this : Run Capacitor No No Yes 3 - Prong Plug Note : If saw does not start when switched on , immediately turn saw off and refer to Troubleshooting . Leaving the switch on will destroy the motor . Grounding Prong Properly Grounded Outlet The power tool is equipped with a 3 - conduc - Power Supply tor cord and grounding type plug listed by , _ WARNING Underwriters ' Laboratories . The ground conductor has a green jacket and is attached Saw is factory wired for 120V opera - to the too ! housing at one end and to the tion . Connect to 120V , 15 - AMP ground prong in the attachment plug at the branch circuit and use 15 - AMP time other end . delay fuse or circuit breaker . Failure to connect in this way could The plug requires a mating 3 - conductor result in injury from shock or fire . grounded type outlet as shown above . If you have an outlet that is of the 2 - prong type , it The saw must be properly grounded . Not all is recommended that you have a qualified outlets are properly grounded . If you are not electrician replace it with a properly ground - sure that your outlet is properly grounded , ed 3 - prong outlet . have it checked by a qualified electrician . 42
Electrical Connections _ , WARNING To maintain proper tool grounding , Grounding Lug if outlet you are planning to use for this power tool is a 2 - prong type do 3 - Prong / _ = _ Make Sure This Is not remove or alter grounding Plug _ ' / ] 1 _ Connected To A prong in any manner . An adapter is available for connecting the plug to 2 - prong receptacles . The green grounding lead or grounding lug extending 2 - Prong Receptacle flom the adapter must be connected to a per - manent ground such as to a properly ground - Note : The adapter illustrated is for use only ed outlet box . if you already have a properly grounded 2 - prong receptacle . Extension Cords Extension Cord Wire Sizes Required for Length 120V ( A . W . G . ) Note : Make sure the proper extension cord is used and is in good condition . ! 10 - 120V The use of any extension cord will cause 0 - 25 Ft 14 some loss of power . Determine the mini - 26 - 50 Ft . 12 mum wire size ( American Wire Gauge No . ( AWG # ) ) extension cord per table . Use only Note : The smaller the gauge numbe _ the 3 - wire extension cords with 3 - prong ground - heavier the cord . For circuits farther away ing type plug and 3 - pole receptacles which [ ' rom the electrical circuit box , wire size accept the tool's plug . must be increased proportionately to deliver ample vo # age to the motor . Motor Protection & Reset Button The motor protector opens the circuit and stops the motor when the motor temperature exceeds a safe level , the motor is overload - Manual Re - Set ed , or a low voltage condition exists . Button ( Red ) When the protector activates , immediately turn saw off , remove yellow key and wail tot motor to cool . Push red re - set button and listen / feel for click to indicate protector is re - sel . If you do not hear / feel a click , molor is still too hot . Wait a while longer and repeat . ( It may take over one hour for the motor to cool sufficiently for protector to reset . ) 43
Electrical Connections Dual Voltage Motors Models 113.196321 and 113.196421 ONLY ! To Change Motor Voltage to 240 A . C . Under normal home workshop conditions , if full voltage is supplied to the motor , your saw will operate efficiently on 120V . If any of the following conditions exist , it will be advisable to have a qualified electrician reconnect the motor for 240V operation : â¢ heavy duty operation â¢ either undersized or overloaded branch circuit serves the saw â¢ power company cannot correct a low volt - age situation . The following procedure to change motor voltage should be performed only by a quali - fied electrician . Note : Whenever cltanging , _ DANGER tlw , n + ' itch position from 120 to 240V , , make To avoid electric shock , unplug saw certain that all necessary steps ( including before changing motor voltage . proper fitsing of the branch circuit ) are com - Pan Head pleted . Screw 1 . Unplug saw . Molor Cover 2 . Remove pan head screw from top of Panel motor cover . Remove motor cover panel at blade end of motor . 3 . Use small screwdriver to slide dual volt - age switch to 240V position . 4 . Re - insrall motor cover panel . 5 . Replace 120V power cord plug with Dual Voltage 240V , 15 amp , 3 - prong plug . Switch 6 . Connect power cord white mad black leads to two " hot " plug blades ; connect power cord grounding wire to plug ground prong . 7 . Plug cord into 240V , 15 amp , 3 - blade receptacle . Make sure receptacle is connect - ed to a 240V A . C . power supply through a 240V branch circuit having at least a 15 amp time delay fuse or circuit breaker . Note : No adapter is available for this o _ pe plug . 44
Crosscutting Straight Bevel Miter Crosscutting Defined Compound Crosscutting is cutting a workpiece to length . The workpiece is held fh - mly against the fence , and the blade is pulled through the work _ iece to make the cut . Straight , bevel , miter , and compound cuts can be made . Rolling Carriage Crosscutting Safety WARNING When saw is turned on , blade can The hazards associated with crosscutting suddenly come forward . To reduce include : exposed blade teeth , rolling car - riage , and thrown workpiece . This section risk of this happening : explains these hazards and tells how to avoid " , ] Keep one hand on saw handle when them or reduce the risk of their happening . turning saw on . Read this section before making any type x ] Adjust leveling feet to make sure radial of crosscut . Follow these steps every time ann slants slightly toward rear . you make a crosscut . Thrown Workpiece , _ CAUTION Exposed Blade Teeth Workpiece could be picked up by WARNING spinning blade and thrown . You During crosscutting , blade teeth might be hit by thrown workpiece . can be exposed . To reduce risk of To reduce risk of thrown workpiece : having fingers , hand or arm cut off : " , ] Make sure installed fence is at least half _ / Correctly install and use guard . as high as the workpiece , and never less than 3 / 4 " . _ / Lower pawls or riving knife to clear fence or workpiece , whichever is high - x / Start and finish cut with blade in rear - er , by 1 / 4 " . Lowered pawls or riving most position , behind fence . knife act as partial barrier to front of " , / Firmly hold workpiece flat on table and blade . up against fence . Cut only one work - " 4Keep hands away from blade and out of piece at a time . blade path . Keep hand holding down _ / Pull blade through workpiece only far workpiece at least 8 " from blade . enough to complete cut , and never Blade can come off table edge beyond more than half the diameter of blade . 30 Â° left miter position . Use right miter Do not touch or move workpieces until position whenever possible . blade has stopped spinning . " 4Do not cut freehand . You will not be _ / Use length stop only on end of work - able to control workpiece . piece which is held down . _ / If blade jams , turn off saw , remove yel - _ / Use table extensions to support work - low key , then free blade . pieces that extend beyond table . 45
Crosscutting Crosscut Kerfs A kerf or shallow cut is needed in the table and fence to serve as a path for the blade and to ensure that the blade cuts all the way through the workpiece . A kerf is needed for each different cutting path . To make an approximately 1 / 16 " deep kerf : 1 . Prepare table : - put fence in font position - tighten table clamps 2 . Prepare blade : - lock blade in crosscut position - lock radial arm at desired miter angle - lock motor at desired bevel angle * - unlock rip lock and push blade to rearmost position , behind fcnce - lower blade * to just clear table - lower pawls or riving knife to clear fence by 1 / 4 " . * raise clearp & stic guard b ( fore changing bevel angle and when lowering beveled blade , otherwise it may jam into table . 3 . Grasp saw handle , then turn saw on . Keep one hand on saw handle through step 6 . 4 . Slowly lower blade until it touches table , then lower one more full turn of crank . 5 . Squeeze handle trigger to fully raise clear plastic guard so it will clear fence . Pull blade through fence and across table as l _ tr as it will go . 6 . Push blade to rearmost position , behind fence , and turn saw off . Keep hand on saw handle until blade stops spinning . / 46
Crosscutting Making Crosscuts Follow these steps to make crosscuts . 1 Prepare table : - put fence in front position - tighten table clamps 2 . Prepare blade : - lock blade in crosscut posilion - lock radial arm at desired miter angle - lock motor at desired bevel angle * - unlock rip lock and push blade to rearmost position , behind fence - lower blade into keff * but not touch - ing kerf bottom ( blade should move freely ) . * raise clear plastic guard before changing bevel angle and when lowering beveled blade , otherwise it may jam into table . 3 Position workpiece against fence , and lower pawls or riving knife to clear fence or workpiece , whichever is higher , by 1 / 4 " . 4 . Grasp saw handle , then turn saw on . Keep one hand on saw handle through step 7 . 5 . Hold workpiece down and against fence . Keep hand at least 8 " away from blade . 6 . Squeeze handle trigger to fully raise clear plastic guard so it will clear fence and workpiece . Pull blade through workpiece but only far enough to complete cut , and never more than half the diameter of blade . 7 . Push blade carriage to rearmost position , behind fence , and turn saw off . Keep hand on saw handle until blade stops spinning . 47
Crosscutting Repetitive Crosscutting Carriage Stop Repetitive crosscutting is the repeated and continuous cutting of many pieces of lumber to the same length . Carriage and length stops can help make this type of crosscutting more efficient . A carriage stop def'mes the distance needed to pull the blade through to complete each cut . This will prevent pulling the blade through more than the recommended dis - tance . To make a carriage stop use Ix2 lumber : i ) cut two pieces , each 2 " long ii ) clamp a piece on each side of radial ann , so blade carriage stops at distance needed to complete cut iii ) check that clamps do not interfere with hand grip on saw handle . A length stop defines the cut length and ensures that all pieces will be cut to the same size . Clamp a piece of 1x2 lumber on the fence to define the cut length . Use a length stop only on the end of the workpleee which is held down . Crosscutting Hints 1 . To extend life of table top , buy auxiliary 5 . When making miter or bevel cuts , use table cover ( see Accessories ) or make one extra force to hold workpiece down because out of 1 / 4 " plywood or fiberboard . Clamp or it tends to move during these types of cuts . nail to original table top , section by , section . 6 . When cutting hard woods , like oak , or If you use nails , nail in the four comers to making compound cuts , keep arm holding make sure blade will not contact nails . saw handle rigid and pull blade through 2 . Make several fences , so each will have slowly . only a few kerfs ( See Cutting Aides ) . Too 7 . To keep cut line accurate , periodically many kerfs will weaken a fence . check blade alignment . 3 . Keep table clean of chips and sawdust . 8 . Do not cut severely warped or crooked 4 . Use sharp blades , and use the right blade workpieces . for each job . 48
Ripping Ripping Defined Ripping is changing the width of a work - piece by cutting along its length . The work - piece is fed into the blade , which rotates in a fixed position , parallel to the fence and a set distance from the fence . A solid fence ( no kerfs ) serves as a guide for the workpiece . Front Fence Rear Fence Position - OR - Position Place the fence in the front position for nar - rower workpieces , or in the rear position for wider ones . o L0 o 0 _ In - Rip and Out - Rip Positions hi - rip and out - tip refer to blade position . In - rip : the blade is toward the column , and the motor is toward the table front . In - tip is recommended because this position allows better visibility of the workpiece and your hands . Use in - rip when you set the blade 1 / 2 to 16 " from the fence . Out - rip : the blade is toward the table front , Outleed Side and the motor is toward the column . Use out - tip only when you set the blade 12 " or more from the fence . Infeed and Outfeed Directions lnfeed and outfeed refer to sides of the blade . In - Rip Position Infeed : the side of the blade where the guard hold down is . Always start a rip cut at the infeed side and push the workpiece through to the ouffeed side . Outfeed : the side of the blade where the pawls and riving knife are . Never start a rip cut at the ouffeed side . This is wrong way Outfeed Side feed . Never put hands on the ouffeed side of the blade when ripping because they can be pulled back into the spinning blade . Pawls / Riving Knife Out - Rip Position 49
Ripping Workpiece Positioning Always set up so that the wider part of the workpiece is between the blade and fence . This gives you greater clearance for push sticks , and allows better stability for feeding the workpiece . Example : To rip 2 " off a 10 " wide board , set blade in in - rip position 8 " from rear fence . Push Sticks and Push Blocks Use push sticks and push blocks instead of the hands to push the work _ iece through to complete cuts . They help keep hands away from the blade , A push block is used with an auxiliary fence . ( see Cutting Aides ) . Use a push block and auxiliary fence when the blade is set 1 / 2 to 2 " from the fence . Use a push stick when the blade is set 2 " or more from the fence . Do not set the blade closer than 1 / 2 " to the fence . The radial saw is the wrong tool for such a narrow cut . A band saw would be more appropriate for this type of cut . Ripping _ . P . _ fety The hazards associated with ripping include : outfeed zone hazard , kickback , and wrong way feed . This section explains these haz - ards and tells how to avoid them or reduce the risk of their happening . Read this section before making any type of rip cut . Follow these steps every time you make a rip cut . 5O
Ripping Outfeed Zone Hazard - _ DANGER a DANGER Rotational force of blade can pull hands and fingers back into blade . Touching , holding , or pulling on outfeed side of workpiece while blade is still spinning will result in fingers , hand or arm being cut off . To reduce risk of outfeed hazard : Set pawls and riving knife ; they act as partial barrier to outfeed side . 4 Start and finish cut from infeed side . " 4Keep both hands on infeed side . Keep hands away from outfeed side . Push workpiece through to complete cut . Do not reach around to pull it . " 4If blade jams , turn saw off , remove yel - low key , then free blade . Kickback Kickback is the uncontrolled propelling of the workpiece back toward the user . , - - WARNING , _ WARNING Kickback can happen when blade is pinched or bound by workpiece . Pinching or binding can happen when : KICKBACK â¢ pawls and riving knife are not used or not set correctly â¢ riving knife is not aligned with blade â¢ blade is not parallel to fence â¢ workpiece is twisted or warped and rocks on table top â¢ pressure is put on ouffeed side of work - piece â¢ workpiece is released before being pushed past pawls â¢ user touches or tries to pull workpiece through outfeed side before blade has stopped spinning . 51
Ripping To reduce risk of kickback : _ / Push workpiece through from infeed to ouffeed side until it is completely past _ / Set pawls and riving knife according to pawls . ripping set - up procedure . Correctly set " , / Use featherboard ( see Cutting Aides ) . riving knife is more likely to prevent workpiece from binding or pinching _ / Keep hands away from outfeed side . blade ; correctly set pawls are more _ / If blade jams , turn saw off , remove yel - likely to grab into workpiece to stop or low key , then free blade . slow kickback if one happens . When cutting composition materials , or _ / Check that riving knife is in line with other materials with one smooth and blade ( see Alignment : Riving Knife to one rough side , put rough side up so Blade ) . pawls will be more likely to grab . _ / Cut only straight workpieces so surface will lie flat on table and edge will stay tight against fence . If you must cut an irregular workpiece , attach a straight edge ( see Cutting Aides ) . Wrong Way Feed WARNING Wrong way feed is ripping by feeding the workpiece into the ouffeed side of the blade . _ kWARNING Rotational force of blade will pull workpiece through violently if work - piece is fed in same direction as blade rotates ( wrong way feed ) . Wrong Way Feed Hands and fingers could be pulled along with workpiece into spinning blade before you can let go or pull back . Fingers , hand or arm could be cut off . Propelled workpiece could hit bystander . To eliminate risk of wrong way feed : _ / Feed workpiece against blade rotation . _ / Set pawls and riving knife ; they act as partial barrier to ouffeed side . 52
Ripping Hold Down Function The hold down must be set correctly during tipping to act as barrier against the infeed side of the blade , to help keep the workpiece flat on the table , and to deflect workpiece chips . It must be lowered to just clear the Set Hold - Down to workpiece . workpiece _ _ _ just clear _ _ The hold down must be re - set each time a different thickness workqgiece is cut . Follow the Ripping Set - Up Procedure to correctly set the hold down . Pawls and Riving Knife Function The pawls and riving knife must be set cor - rectly during tipping to reduce the risk of kickback , to prevent wrong way feed , and to act as a barrier to the hazardous outfeed side of the blade . Set Pawl level The riving knife rests on the table . It keeps on workpiece the workpiece kerf open . This reduces the _ _ J _ chances that the cut workpiece will spring closed and pinch the blade . Pinching the blade is a cause of kickback . Set Riving Knife The pawls rest level on the upper surface of fully down the workpiece . During cutting they " allow the workpiece to pass freely from the infeed to the outfeed side , but help stop the kickback motion from ouffeed to infeed side by grab - bing into the workpiece surface . The pawls must be re - set each time a differ - ent thickness workpiece is cut . Follow the Ripping Set - Up Procedure to correctly set the pawls and riving knife . 53
Ripping WARNING Ripping Set - up Procedure If workpiece is pushed along fence Follow these stepsbefore ripping . with kerfs , workpiece could get These steps must be repeated each time a caught on kerf , pinch blade and different thickness workpiece is ripped . A cause kickback . Do not use cross - kerf must be made for each different cutting fence for ripping . width cut . Also see the special notes for bevel set - up that follow this section . 1 . Prepare table : - insert solid ( no kerfs ) fence ( Note : Use auxiliary fence when blade is set 1 / 2 to 2 " from fence ( See Cutting Aides ) - tighten table clamps . 2 . Prepare blade : - lock radial arm at 0 Â° miter - lock blade in in - rip position * - lower blade to just clear table - lock blade carriage desired distance from fence . Note : Make sure wider part of worlqoiece will be between blade and fence . In - Rip Set - Up * use out - rip position for rips 12 " or wider . 3 . Make kerf : a ) turn saw on b ) lower blade about 1 / 16 " into table c ) turn saw off and remove yellow key . 4 . Place workpiece parallel to and up against blade . * * Note : Workp & ce will be between blade and table front . 5 . Lower hold down * * to workpiece , then raise slightly so it just clears top surface of workpiece . Lock in place . 6 . Lower riving knife to table . Lower pawls to workpiece surface . * * Move workpiece toward outfeed side until one set of pawls rests level on workpiece surface . Lock in place . * * bevel set - up : see special notes , next page Setting Guard For Rip Cut 54
Ripping 8 . Remove workpiece from table . 9 . Ready push stick or push block . 10 . Set up table extension ( s ) and support their outer ends . Do not use another person to support workpieces because this can cause kickback and it exposes helper to potential hazards at outfeed side . Special Notes for Bevel Set - Up _ CAUTION Bevel ripping creates unique prob - lems of visibility and feeding . Before cutting , check the set - up using both in - rip and out - rip . Use the position that gives the best combination of workpiece visibility and push stick clearance . , _ WARNING Bevel the edge that is not against the fence . 1 . When setting bevel angle , raise radial arm to allow sufficient clearance for blade and guard to not jam in table . 2 . When blade is beveled manually raise clear plastic guard before lowering blade to table or kerf , otherwise it may jam in the table . 3 . To set hold down , place workpiece direct - ly under guard nose , rather than parallel to blade . 4 . To set pawls , place workpiece directly under set of pawls closer to table . This set of pawls will keep contact with workpiece sur - face . Making Rip Cuts Follow these steps to make in - rip cuts . For out - rip cuts , reverse hand functions ; that is , put right hand on table and use left hand to support and push workpiece . In - ripping 1 . Follow ripping set - up procedure . 55
Ripping 2 . Insert yellow key and turn saw on . 3 . Stand at infeed side and out of line of workpiece , in case of kickback . Start and finish cut from infeed side . 4 . Put workpiece on table , in front of hold down , and tight against fence . To hold work - piece in position , put left hand on table , at least 8 " in front of hold down , and lightly press fingers against workpiece . Support workpiece with table extension or right hand . , _ CAUTION For large workpieces use a feather - board in place of your hand on the table . It gives better support . ( See cutting aides ) Keep Hand Back 8 " 5 . With fight hand , push workpiece under hold down and into blade . Keep left hand Out - ripping fixed on table , applying slight pressure to keep workpiece against fence . 6 . Use right hand to continue to apply feed pressure to part of workpiece close to fence . Keep hand at least 8 " in front of hold down . Note : Most worbpieces will automatically raise clear plastic guard as they pass from infeed to ouOreed side . Unusually tall and narrow workpieces may not raise clear guard . When this happens , push guard tab to raise guard , then release tab when guard rests on top of workpiece surface . _ IL CAUTION Pushing guard tab means using only one hand to control workpiece . While pushing tab , use extra care to guide workpiece and to keep hand at least 8 " in front of hold down . Tab Release tab as soon as clear guard Keep Hand rests on workpiece . Back 8 " 7 . When end of workpiece gets to table , use push stick or block , instead of hand , on part In - ripping of workpiece between blade and fence to push until workpiece is completely past pawls . 8 . Turn saw off and wait for blade to stop spinning before touching workpieee . 56
Ripping Dado Blades , Molding Heads See Accessories for information on safety , installation and use of dado blades and molding heads . Edging Edging is the use of a dado blade or molding head in the horizontal position . It is an advanced technique that requires a molding head guard and a sr , ecial fence . See Accessories for information on safety , instal - lation and use of dado blades and molding heads for edging . See Cutting Aides for information on making the special fence . Ripping Hints 1 . To extend life of table top , buy an auxil - iary table cover ( see Accessories ) , or make one out of 1 / 4 " plywood or fiberboard . Clamp or nail to original table top , section by section . If you use nails , nail in the four comers to make sure blade will not contact nails . 2 . Keep table clean of chips and sawdust . 3 . Use shmp blades . 4 . Use the right blade for each job . 5 . For workpiece with one smooth and one rough surface , such as paneling or finished fiberboard , cut with rough surface up so pawls will be more likely to grab in case of kickback . 6 . _ ib keep cut line accurate , periodically check blade alignment . 7 . If you must cut an irregular workpiece , attach a sn - aight edge ( see Cutting Aides ) . 57
Cutting Aides SLIGHTLY LESS THAN Push Stick Before cutting any wood on your saw , study THICKNESS OF WORKPIECE 3 / 4 " UP TO 3 / 8 " all of the Crosscutting and Ripping - X Instructions found on pages 41 through 53 . As you learn new radial arm saw wood - working techniques , you'll see that many â¬ types of cuts need different support and feeding devices , known as jigs or fixtures . 90 Â° NOTCH 1 / 2 " _ They can help you make cuts more accurate - - . , , II ] 2 " ly . By helping to steady the workpiece and Material For Push Block keep you away from the blade , they can help _ ' _ At Least 12 " you safely use your saw for certain cuts . Many people custom build their own jigs and fixtures . Jigs and fixtures are often 7 designed for a particular cut . At Least 3 / 8 " THICK PLYWOOD You can use your radial saw to easily make 5 - 5 / 8 " BASE many jigs and fixtures . To get you started , _ ! we've included instructions for some simple ones . After you have made a few practice At Least 12 " _ - - cuts , make up these jigs before starting any projects . Make the push stick first . 1 Push Sticks At Least 3 / 4 " THICK PLYWOOD Make the push stick using a piece of 1 x 2 . 5 " HANDLE ( see drawing top right tor dimensions and V shapes ) Push Block Cutting out the Base There are any number of ways to properly cut your v , ork pieces to make a push block . _ 2 - 1 / 2 " ( save ) The following steps describe one way you ] . - 4 " Th Cut 1 st Cut can proceed . Making the base : â¢ Start with a piece of 3 / 8 " plywood at least 5 - 5 / 8 " wide or wider and 12 " long or 2 nd Cut longer . 12 " â¢ Make two ripcuts . Perform the first ripcut along the long side of the 3 / 8 " plywood to Creating the Notch create a 3 / 8 " wide strip . Next ripcut the 3 / 8 " plywood to a width of 5 - 1 / 8 " . â¢ Crosscut the 3 / 8 " plywood to 12 " long . â¢ Crosscut a 2 - 1 / 2 " piece offof the 3 / 8 " 1 st Cut wide by 3 / 8 " thick strip and save this short i 2 nd Cut 4 - 3 / 4 " piece for later . - _ - - - - _ - Ji - - - 2 - 112 " â¢ The next cuts will create the 3 / 8 " by 9 - 1 / 2 " notch in the base . Mark the long edge Finished Base of the board 2 - 1 / 2 ' " from one end . Make a 12 " = 1 crosscut into the edge , stopping about 3 / 4 " into the board . Set the saw to the in - rip position and rip the width lo 4 - 3 / 4 " along the same edge as the stopped crosscut . _ THESE I 5 " i ] 8 " Stop the ripcut where the two cuts inter - EDGES 4 - 3 / 4 " sect . Turn off the saw and remove the base MUST BE + , + , + PARALLEL piece . The base should [ lOW measure as shown . 58
Cutti Aides Cutting out the handle Making the handle : â¢ Miter crosscut a piece of 3 / 4 " fllick ply - wood to the shape and size shown . The mitered comers can be any size that looks like the drawing ( about 1 - 1 / 2 " by 1 - 1 / 2 " ) . 1 - 112 " V Jl 5 " _ 1 - 1 / 2 " Putting it together : â¢ Using good quality wood working glue , glue the 2 - 1 / 2 " strip saved earlier to the base as shown . Important : Do not use 12 " nails or screws . This is to prevent dulling of the saw blade in the event you cut in to the push block . Assembly â¢ Position the handle at the edge of the ply - wood base as shown . Fasten them togeth - er with glue and wood screws . Important : Make sure the screw heads do not stick out from the bottom of the only joint base . The bottom must be flat and smooth enough to slide along the auxiliary fence you are now ready to make . Auxiliary Fence : Making the base : â¢ Start with a piece of 3 / 8 " thick plywood at least 5 - 1 / 2 " ' , vide and at least 30 " long . â¢ Cut the piece to 5 - 1 / 2 " wide and 30 " long . Making the side pieces : â¢ Using 3 / 4 " plywood at least 30 " long , rip - I cut one piece 2 - 1 / 4 " wide and one piece I 3 - 1 / 4 " wide . Screwhead must be AI [ â¢ Separately , crosscut both pieces to 30 " flush or recessed long . Putting R together : â¢ Glue and then fasten with screws the side pieces to the base as shown . Make sure the edge of the base and the face of the side piece are parallel as indicated in the note next to the drawing . Important : Make sure the screw or nail heads do not stick out from the bottom of the base . The bot - tom must be flat and smooth enough to Auxiliary Fence rest on the saw table without rocking . - 3 / 4 " PLYWOOD 2 - 1 / 4 " L \ \ \ 4 - 3 / 4 " \ Glue - _ 3 / 8 " ' X I THIS FACE AND Use 2 screws in at least 2 equally THIS EDGE MUST spaced locations _ long fence BE PARALLEL ( for a total ot 4 screws ) 59
Cutting Aides Clamp the featherboard to the front table , so that the angled edge of the featherboard is against the workpiece on the infeed side of the blade . Do not clamp the featherboard against the cut off part ( out - feed side ) of the workpiece . If clamped to the outfeed side , the featherboard can squeeze the kerf closed , put binding pressure on the blade , and cause kickback . Straight Edge for Irregular Workpiece _ WARNING If you try to rip an irregular work - piece , it could bind blade and cause kickback . ff the workpiece you want to rip does not have a straight edge , attach a straight - edged board to the workpiece : a ) place irregular side of workpiece against fence b ) put straight - edged board on top of workpiece and against fence c ) tack straight edged board to work piece . Note : Straight - edged board must not extend beyond leading end of workpiece and should cover workpiece width only enough to pass between blade and fence . Note : Use fence at least as high as com - bined heights of workpiece and straight - edged board . 6O